Locking mechanism for flooring boards

ABSTRACT

A locking system for floor boards comprises a plurality of floor boards and a plurality of locking devices. Each floor board has two tongues on one lateral side and another tongue and a locking groove on the opposite lateral side. The floor board also has two grooves on its bottom side. The locking device has three protruding gripping extensions. Few locking devices are placed on each floor board before the floor boards are sent to a job site. At the job site, two adjacent floor boards are assembled together by inserting the tongue of one board into a space defined by the locking device and the tongues of the adjacent board. The tongues are further secured in place by compression of flexible buffers located at each protruding gripping extension.

RELATED APPLICATION

This application is a divisional application of and claims priority toconcurrently pending U.S. patent application Ser. No. 11/956,057 forLOCKING MECHANISM FOR FLOORING BOARDS, filed on Dec. 13, 2007, whichwill be issued on Oct. 5, 2010, as U.S. Pat. No. 7,805,903.

FIELD OF THE INVENTION

The invention relates to wood flooring, and more particularly, to alocking mechanism for flooring boards.

BACKGROUND OF THE INVENTION

Different systems have been used to ease construction of wood flooring;however, most of them present some deficiency especially in relation toengaging thin laminate “floating floor” surfaces. Traditional woodfloors, which are joined by means of glued tongue-and-groove joints,wood floor panels have recently been developed which do not require theuse of glue and instead are joined mechanically by means of so-calledmechanical joint systems. These systems contain locking means which lockthe panels horizontally and vertically. Typically, manufacturers oflaminate flooring panels have produced flooring products that containboth a tongue and a groove profile within the same flooring panel. Thetongue profile is machined into one side and one end of the panel withthe groove being machined into the opposite side and end of the samepanel. The mechanical joint systems can be made by machining the core ofa panel. One exemplary locking device is disclosed by U.S. Pat. No.6,532,709 B2. Alternatively, parts of the locking system can be made ofa separate material which is integrated with the floor panel, i.e.joined with the floor panel even in connection with the productionthereof.

Besides the locking means provided by the flooring panels, the adjacentpanels are further secured by locking devices. The locking devicetypically is a strip with salient features that engages the lockingdevice onto two adjacent flooring panels. One exemplary locking deviceis disclosed by the same U.S. patent cited above.

Normally, one or more locking devices are affixed first onto a floorpanel and the tongue of a second flooring panel is inserted into thegroove of a second flooring panel. The second flooring panel is furthersecured in its place by the locking device. The insertion of the tonguein the groove forms a lock.

However, the lock between two adjacent flooring panels sometime becomes“loose,” allowing some movement between the two flooring panels. Themovement between the adjacent flooring panels generates squeaking soundand it is hard to eliminate. The lock also requires precision millingfor the lock works properly and small deformation of flooring panelafter milling will render the lock and locking device unusable.

Therefore, there is a need for an apparatus that reduces relativemovement between two adjacent flooring boards and simplifies flooringboard manufacturing process, and it is to this apparatus the presentinvention is primarily directed to.

SUMMARY OF THE INVENTION

The present invention provides a floor board. The floor board has a topside, a bottom side, a first short side, a second short side opposite ofthe first short side, a first long side, and a second long side oppositeof the first long side. Each long side has a length, and the first longside has a first tongue and a second tongue along the length of thefirst long side. The first tongue is defined by a first upper abutmentsurface substantially parallel to the top side and a first lowerabutment surface substantially parallel to the first upper abutmentsurface, and the second tongue is defined by a second upper abutmentsurface substantially parallel to the top side and a second lowerabutment surface substantially parallel to the second upper abutmentsurface. The second long side has a third tongue and a first lockinggroove along the length of the second long side. The third tongue isdefined by a third upper abutment surface substantially parallel to thetop side and a third lower abutment surface substantially parallel tothe third upper abutment surface. The first locking groove is defined bya first upper groove surface substantially parallel to the top side andthe third upper abutment surface.

In yet another embodiment of the invention there is also providedanother floor board with a profile. The profile having a top side, abottom side, a first long side, and a second long side opposite of thefirst long side, each long side having a length. The first long side hasa first tongue and a second tongue along the length of the first longside and the second long side has a third tongue and a first lockinggroove along the length of the second long side.

In yet another embodiment of the invention, there is provided anotherfloor board with a profile. The profile has a top side, a bottom side, afirst long side, and a second long side opposite of the first long side,each long side having a length. The first long side has a first tongueand a second tongue along the length of the first long side and thesecond long side has a third tongue along the length of the second longside.

BRIEF DESCRIPTION OF THE DRAWINGS

Features and advantages of embodiments of the invention will becomeapparent as the following Detailed Description proceeds, and uponreference to the Drawings, where like numerals depict like elements, andin which:

FIG. 1A illustrates a perspective view of a locking device according toone embodiment of the invention;

FIG. 1B illustrates a profile of the locking device shown in FIG. 1A;

FIG. 2A illustrates a perspective view of a floor board according to oneembodiment of the invention;

FIG. 2B illustrates the profile of a floor board according to oneembodiment of the invention;

FIG. 3 illustrates a locking device prior being attached to a floorboard on a job site according to one embodiment of the invention;

FIG. 4 illustrates a locking device after being attached to a floorboard on a job site according to one embodiment of the invention;

FIG. 5 illustrates assembly of two adjacent floor boards;

FIG. 6A illustrates two floor boards after being joined using a lockingdevice;

FIG. 6B depicts two floor boards in a joined position using analternative locking device;

FIG. 6C depicts two floor boards in a joined position using yet analternative locking device; and

FIG. 7 depicts a perspective view from the bottom of two floor boardsjoined with a locking device.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a locking system for floor boards. Floorboard may be made from solid wood or composite wooden material withseveral layers or other suitable material. Each floor board has aprofile with specially designed features that allow one floor board beeasily joined with an adjacent floor board. The joined floor boards arefurther locked together with locking devices strategically distributedalong the seam of two joined floor boards. FIG. 1A illustrates oneembodiment of a locking device 100 and FIG. 1B illustrates a profile ofthe locking device 100. The locking device 100 is preferably made from aresilient and flexible material, such as steel, aluminum, plastic,rubber, etc. The locking device 100 has a base 102 with a first end 104and a second end 106. A first protruding gripping extension 122 islocated at the first end 104 and a second protruding gripping extension120 is located at the second end 106. The top of the first protrudinggripping extension 122 is preferably rounded, or alternatively havingthe edge facing the second protruding gripping extension 120 rounded. Areceiving groove 116 is preferably formed on the first protrudinggripping extension 122 or at the junction of the first protrudinggripping extension 122 and the base 102. The receiving groove 116 isformed in such way that a flexible buffer 108 can be inserted therein.The flexible buffer 108 has preferably a round shape, but other shapesmay also be used. The flexible buffer 108 is preferably made from rubberor plastic, or other suitable material. The flexible buffer 108 can be,preferably, slid into and out from the receiving groove 116. However,flexible buffer 108 may also otherwise be jammed into the receivinggroove 116.

The second protruding gripping extension 120 has a top that extendsbeyond the second protruding gripping extension 120. The top has atrapezoidal form with the top part being slightly smaller than thebottom part and an angle θ formed between a vertical plan touching thecorner of the bottom part and one side of the trapezoidal form. Theangle θ helps to form a tooth 110 on the top of the second protrudinggripping extension 120. Similar to the first protruding grippingextension 122, the second protruding gripping extension 120 may alsohave a receiving groove 116 in which a flexible buffer 108 may beinserted.

Optionally, the locking device 100 has also a third protruding grippingextension 112 located between the first protruding gripping extension122 and the second protruding gripping extension 120. The thirdprotruding gripping extension 112 has a horizontal platform 118 thatextends beyond the third protruding gripping extension 112. Thehorizontal platform 118 has a lower abutment surface 114 and a topsurface 124. Alternatively, the horizontal platform 118 may have atrapezoidal profile similar to that of the tooth 110. The profile of alocking device 100 without the third protruding gripping extension 112is shown in FIG. 6C. Optionally, the third protruding gripping extension112 has a receiving groove 116 in which a flexible buffer 108 may beinserted. The profile of a locking device 100 without the thirdprotruding gripping extension 112 and without the flexible buffer 108 isshown in FIG. 6B.

FIG. 2A is a perspective view of a floor board 200 according to oneembodiment of the invention and FIG. 2B is a profile of the floor board200. The floor board 200 may be made from solid wood, a manufacturedmulti-layer wood material, or a composite synthetic-wood material. Thefloor board 200 has a wooden top surface 202, two tongues 234, 208 alongthe length of one lateral side, and another tongue 206 along the lengthof an opposite lateral side. These tongues are reflected by the profile204.

The tongue 234 is formed by an upper abutment surface 226 and a lowerabutment surface 228 and the tongue 208 is defined by another upperabutment surface 220 and another lower abutment surface 238. The upperabutment surfaces 226 and 220, lower abutment surfaces 228 and 238 aresubstantially parallel to the top surface 202. The lower two corners222, 224 of the tongue 208 is preferably rounded. Optionally, the tongue234 may be covered with a coating of rubber, plastic, thin film, orother suitable material that minimize friction.

On the opposite side of the tongue 234, there is a locking groove 240for receiving the tongue 234 from an adjacent floor board. The lockinggroove 240 is defined by an upper groove surface 216 and an upperabutment surface 218. The upper groove surface 216 is substantiallylined up with the upper abutment surface 226 and the upper abutmentsurface 218 is substantially lined up with the lower abutment surface228. There is a tongue 206 below the locking groove 240. The tongue 206is defined by the upper abutment surface 218 and a lower abutmentsurface 236. Three corners 210, 212, and 214 of the tongue 206 arepreferably rounded. The bottom of the floor board 200 has two lockinggrooves 230, 232 for receiving the second protruding gripping extension120 and the first protruding gripping extension 122 respectively whentwo adjacent floor board 200 are joined using a locking device 100.

The thickness H of the profile 204 is slightly larger than thickness h,thus a locking device 100 can be placed beneath the joined floor boards200 without raising the high of the final floor boards. Optionally, thethickness H and thickness h can be the same or similar, thus the bottomof the floor boards 200 floats above the underlayment. Preferably, thelower abutment surface 238 is substantially lined up with the lowerabutment surface 236. However, because of use of multiple tongues 206,208, 234, and the locking device 100, the present invention eliminateshigh precision milling commonly used in the manufacturing of floorboards 200, thus reduces the manufacturing cost of floor boards 200.

Preferably, few locking devices 100 are placed on each floor board 200prior the floor boards 200 are shipped to a job site. There is no needto cover entirely either lateral side of a floor board with a longlocking device as required by prior art floor boards and lockingdevices. When the floor boards 200 arrive at the job site, installerscan easily assemble the floor boards 200 together. As it would normallyhappen, the floor boards may need to be cut at the job site andadditional locking devices 100 may need to be fixed onto a floor board200. FIG. 3 depicts a locking device 100 prior to be fixed onto a floorboard 200. The tongue 208 is slid into a groove defined by the base 102,the second protruding gripping extension 120, and the third protrudinggripping extension 112. The width of the second protruding grippingextension 120 along with the tooth 110 is preferably slightly wider thanthe width of the locking groove 230 such that the second protrudinggripping extension 120 cannot be inserted into the locking groove 230without application of an external force 302.

After applying the external force 302, for example, by hammering, thesecond protruding gripping extension 120 of the locking device 100 canbe forced into the locking groove 230 and the second protruding grippingextension 120 is prevented from detaching from the locking groove 230 bythe tooth 110 that is jammed into the surface of the locking groove 230as it is shown in FIG. 4. The tongue 208 is locked into the position bythe base 102 and lower abutment surface 114 of the third protrudinggripping extension 112. The tongue 208 is also secured by compressionagainst the flexible buffer 108. Minor imperfections of the tongue 208can be easily compensated by locking provided by the base 102 and thelower abutment surface 114 and compression by the flexible buffer 108along the length of the locking device 100. The locking device 100 canalso be removed on a job site if needed. To remove a locking device 100simply apply a large force 402 at the locking device 100 as shown inFIG. 4. The removed locking device 100 can be re-installed at differentlocation on the same floor board 200.

FIG. 5 illustrates assembly 500 of two adjacent floor boards 200. Afirst floor board 504 has a locking device 100 attached. The tongue 206of a second floor board 506 is inserted into a groove defined by thefirst protruding gripping extension 122, the base 102 of the lockingdevice 100, the third protruding gripping extension 112, and the tongue234 of the first floor board 504. Because the lower corners of thetongue 206 and the top of the first protruding gripping extension 122are rounded, the insertion in the direction 502 is made easier. As thetongue 206 of the second floor board 506 is slid into the abovedescribed groove, the tongue 234 of the first floor board 504 is alsoslid into the locking groove 240 of the second floor board 506. Thefitting of the tongue 234 into the locking groove 240 provides a precisefitting between two adjacent floor boards 200 and also levels twoadjacent floor boards 200. If the tongue 234 has a coating or coveredwith a film, the friction noise between two adjacent floor boards 234will be further reduced. It is understood by those skill in the art thatthe tongue 234 and the corresponding locking groove 240 may havedifferent shapes. One example of a different shape is the abutmentsurfaces between the tongue 234 and the locking groove 240 are notparallel to the top surface 202.

FIG. 6A depicts two adjacent floor boards 200 after being assembledtogether. The two adjacent floor boards 200 are locked in place byengagement of the tongue 234 of one floor board into the locking groove240 of another floor board along the entire length of two floor boards200. The two adjacent floor boards 200 are also locked in place byplacement of the tongue 206. The tongue 206 is secured in place by thelower abutment surface 228 of the tongue 234 and the base 102 of thelocking device 100. The tongue 206 is also secured by compressionagainst the flexible buffer 108 on the first protruding grippingextension 122 and the flexible buffer 108 on the third protrudinggripping extension 112. Because of use of two tongues 234, 206 and thecompression of flexible buffers 108, two adjacent floor boards 200 aretightly joined and thus reducing squeaking sound (noise produced byfriction between adjacent floor boards). The squeaking sound is furtherreduced with use of flexible buffers 108.

Double locking provided by the tongue 206 and tongue 234 helps to lockfirmly two adjacent floor boards 200 even each floor board 200 isslightly deformed. The deformation may be caused by many factors, amongthem, variation in moisture, temperature, milling variation, or woodinterior stress. Because of the special nature of the design provided bythe invention, the successful rate for locking tightly adjacent floorboards is greatly increased. The relative vertical moves between twoadjacent floor boards 200 are reduced by the double lock nature of thepresent invention. The risk of unlocking after the installation is alsogreatly reduced. The gaps between the floor boards 200 resulting fromshrinking or expansion of the floor boards 200 are reduced or eliminatedbecause of a strong squeeze force provided by the double locking.

FIG. 6B illustrates joining of two floor boards 200 similar to what isshown by FIG. 6A except for the locking device 100. The locking deviceused in FIG. 6B does not have a flexible buffer 108 along the thirdprotruding gripping extension 112. The tongue 206 is still secured inplace by the lower abutment surface 228 of the tongue 234 and the base102 of the locking device 100, but the tongue 206 is now secured only bycompression against the flexible buffer 108 on the first protrudinggripping extension 122. Even without a flexible buffer 108 on the thirdprotruding gripping extension 112, this configuration still offersdouble locking provided by the tongue 206 and tongue 234, which resultsin a firm lock without squeaking sound even two floor boards 200 areslightly deformed.

FIG. 6C illustrates joining of two floor boards 200 using a lockingdevice 100 that does not have a third protruding gripping extension 112.Two floor boards 200 are tightly joined by the double locking providedby the tongue 206 and tongue 234 and the double locking mechanism issecured by the first protruding gripping extension 122 and secondprotruding gripping extension 120. The third tongue 206 is inserted intoa groove defined by the lower abutment surface 228 of the first tongue234, the base 102 of the locking device 100, the first protrudinggripping extension 122, and the third tongue 208 of an adjacent floorboard 200. The dimensions of the tongues 206 and 208 used in thislocking configuration may be different from the dimensions of thetongues 206 and 208 using in other locking configurations. Optionally,glue may be used on the bottom side of the tongue 208 to stabilize thelocking device 100.

FIG. 7 is an illustration 700 of two joined floor boards 200 with upsidedown view. As it can be seen, two adjacent floor boards 200 can bejoined using few locking devices 100. There is no need to use longlocking devices that cover the entire length of a floor board; thus thequantity of locking devices 100 used in a job site can be reduced.

The present invention makes easy on-site installation of floor boards200 with use of locking devices 100. The locking devices 100 can beproduced cheaply in large scale, assembled with flexible buffer 108, andpre-installed on each floor board 200. There is no need to useadditional fixing devices, such as nails or screws. Each locking device100 can be cut short for easy handling. The installation shown in FIGS.6A and 6B can be reversed if needed. If an installer made a mistakeduring the installation, he can simply remove the floor board 200 thatwas installed in error and re-install it without damaging the lockingdevice 100 or the floor boards 200.

Though the invention is described above using floor boards 200 asexamples, the invention can be easily applied to other uses, such aswall panels, external sidings, roof panels, and ceiling panels. Thelocking device 100 can be used with boards and panels of differentmaterials, such as laminate panels, plastic panels, cement panels, steelpanels, etc.

The terms and expressions which have been employed herein are used asterms of description and not of limitation, and there is no intention,in the use of such terms and expressions, of excluding any equivalentsof the features shown and described (or portions thereof), and it isrecognized that various modifications are possible within the scope ofthe claims. Other modifications, variations, and alternatives are alsopossible. Accordingly, the claims are intended to cover all suchequivalents and combinations among embodiments described herein above.Dimensions in the drawings here presented are not to the scale unlessotherwise indicated.

1. A floor board comprising: a top side; a bottom side; a first shortside; a second short side opposite of the first short side; a first longside; and a second long side opposite of the first long side, each longside having a length, wherein the first long side having a first tongueand a second tongue along the length of the first long side, the firsttongue being defined by a first upper abutment surface substantiallyparallel to the top side and a first lower abutment surfacesubstantially parallel to the first upper abutment surface, the secondtongue being defined by a second upper abutment surface substantiallyparallel to the top side and a second lower abutment surfacesubstantially parallel to the second upper abutment surface, and thesecond long side having a third tongue and a first locking groove alongthe length of the second long side, the third tongue being defined by athird upper abutment surface substantially parallel to the top side anda third lower abutment surface substantially parallel to the third upperabutment surface, the first locking groove being defined by a firstupper groove surface substantially parallel to the top side and thethird upper abutment surface.
 2. The floor board of claim 1, wherein thebottom side further comprises a second locking groove along the lengthof the first long side and a third locking groove along the length ofthe second long side.
 3. The floor board of claim 1, wherein the firsttongue being covered by a coating.
 4. The floor board of claim 3,wherein the coating being made from rubber.
 5. The floor board of claim1, wherein the first upper abutment surface being lower than the topside.
 6. The floor board of claim 1, wherein the third tongue havingrounded corners.
 7. The floor board of claim 1, wherein the secondtongue having rounded corners.
 8. A floor board comprising: a profilehaving a top side, a bottom side, a first long side, and a second longside opposite of the first long side, each long side having a length,wherein the first long side having a first tongue and a second tonguealong the length of the first long side and the second long side havinga third tongue and a first locking groove along the length of the secondlong side.
 9. The floor board of claim 8, wherein the first tongue beingdefined by a first upper abutment surface substantially parallel to thetop side and a first lower abutment surface substantially parallel tothe first upper abutment surface.
 10. The floor board of claim 9,wherein the second tongue being defined by a second upper abutmentsurface substantially parallel to the top side and a second lowerabutment surface substantially parallel to the second upper abutmentsurface.
 11. The floor board of claim 10, wherein the third tongue beingdefined by a third upper abutment surface substantially parallel to thetop side and a third lower abutment surface substantially parallel tothe third upper abutment surface, the first locking groove being definedby a first upper groove surface substantially parallel to the top sideand the third upper abutment surface.
 12. The floor board of claim 8,wherein the distance between the top side and the bottom side defines afirst thickness and the distance between the top side and the bottom ofthe third tongue defines a second thickness, the first thickness beinglarger than the second thickness.
 13. The floor board of claim 8,wherein the second tongue and the third tongue having rounded corners.14. A floor board comprising: a profile having a top side, a bottomside, a first long side, and a second long side opposite of the firstlong side, each long side having a length, wherein the first long sidehaving a first tongue and a second tongue along the length of the firstlong side and the second long side having a third tongue along thelength of the second long side.
 15. The floor board of claim 14, whereinthe first tongue being defined by a first upper abutment surfacesubstantially parallel to the top side and a first lower abutmentsurface substantially parallel to the first upper abutment surface. 16.The floor board of claim 15, wherein the second tongue being defined bya second upper abutment surface substantially parallel to the top sideand a second lower abutment surface substantially parallel to the secondupper abutment surface.
 17. The floor board of claim 16, wherein thethird tongue being defined by a third upper abutment surfacesubstantially parallel to the top side and a third lower abutmentsurface substantially parallel to the third upper abutment surface. 18.The floor board of claim 17, further comprising a locking groove definedby a first upper groove surface substantially parallel to the top sideand the third upper abutment surface.
 19. The floor board of claim 14,wherein the distance between the top side and the bottom side defines afirst thickness and the distance between the top side and the bottom ofthe third tongue defines a second thickness, the first thickness beinglarger than the second thickness.
 20. The floor board of claim 14,wherein the second tongue and the third tongue having rounded corners.